Crystalline aluminosilicates



United States Patent "ice 3,508,867 CRYSTALLINE ALUMINOSILICATES Vincent J. Frilette, Delaware Township, Camden County, N..I., and Paul B. Weisz, Media, Pa., assignors to Mobil Oil Corporation, a corporation of New York No Drawing. Continnation-in-part of application Ser. No. 754,915, Aug. 14, 1958. This application Dec. 21, 1961, Ser. No. 161,242

Int. C1. C01! 33/28 US. Cl. 231I1 1 Claim ABSTRACT OF THE DISCLOSURE Crystalline aluminosilicates of the molecular sieve type having non-metallic ions such as hydrogen or ammonium ions in combination with metallic cations having a valence greater than one selected from Groups I-B through VIII of the Periodic Table. The compositions are prepared by treating a crystalline aluminosilicate with a solution containing the desired ions until such time as the aluminosilicate is base-exchanged so as to contain combinations of the aforementioned metallic and nonmetallic cations. The compositions have particular use as catalysts for the conversion of hydrocarbons.

This application is a continuation-in-part of copending application Ser. No. 754,915 filed Aug. 14, 1958, now US. Patent 3,140,322.

This invention relates to catalyst compositions and more particularly to aluminosilicate catalysts containing hydrogen ions and metal cations, and their method of preparation.

A considerable number of materials have heretofore been proposed as catalysts for the conversion of hydrocarbons into one or more desired products. In the catalytic cracking of hydrocarbon oils, for example, wherein hydrocarbon oils of higher boiling range are converted into hydrocarbons of lower boiling range, notably hydrocarbons boiling in the motor fuel range, the catalysts most widely used are solid materials which behave in an acidic manner whereby hydrocarbons are cracked. Although acidic catalysts of this type possess one or more desired characteristics, a great many of these catalysts have undesirable characteristics, such as lack of thermal stability, availability, or mechanical strength, etc., whereby a wide range of suitable properties cannot be maintained. Synthetic silica-alumina composites, the most popular catalysts known to have been proposed heretofore, provide limited yields of gasoline for a given yield of coke and further suffer the disadvantage of rapidly deteriorating and becoming inactive in the presence of steam, particularly at temperatures above 1000 F. Other catalysts less widely used include those materials of an argillaceous nature, e.g., bentonite and montmorillonite, which have been treated with acid to bring out their latent cracking characteristics. Catalysts of this general type are relatively inexpensive, but are only moderately active and exhibit a decline in activity over periods of many conversion and regeneration cycles. Some synthetic materials, such as silica-magnesia complexes, are more active than conventional silica-alumina catalysts and undergo normal aging, but have limited utility because of their poor product distribution as evidenced, for example, by low octane number of the gasoline.

Other disadvantages of heretofore proposed catalysts include poor activity, chemical stability and product distribution in obtaining desired yields of useful products.

The present invention is based on the discovery that aluminosilicates containing from 0.5 to 1.0 equivalent of certain ions of positive valence per gram atom of alu- 3,508,867, Patented Apr. 28, 1970 minum are highly active hydrocarbon conversion catalysts. The ions of positive valence contained in the aluminosilicates of this'invention consist of from 0.01 to 0.99 equivalent of hydrogen ion per gram atom of aluminum and from 0.99 to 0.01 equivalent per gram atom of aluminum of cations of metals selected from Groups I-B through VIII of the Periodic Table. The

catalysts of this invention possess a wide spectrum in magnitude of catalytic activity; can be used in relatively small concentrations; and permit certain hydrocarbon conversion processes to be carried out under practicable and controllable rates at lower temperatures, than those previously employed. In the catalytic cracking of hydrocarbon oils into hydrocarbon products of lower molecular weight, the reaction rates per-unit volume of catalyst that are obtainable by the catalysts of the invention vary up to many thousand times the rates achieved with the best siliceous catalysts heretofore proposed. The present invention furthermore provides a means whereby aluminosilicate materials having no internally available surfaces and only external particle surface areas can be readily converted to useful catalysts which thus broadens considerably their realm of practical utility.

The high activity catalysts contemplated herein are aluminosilicate compositions which are strongly acidic in character as a result of treatment with a fluid medium containing at least one metallic cation and a hydrogen ion or ion capable of conversion to a hydrogen ion. Inorganic and organic acids broadly represent the source of hydrogen ions; metallic salts the source of metal cations; and ammonium compounds the source of cations capable of conversion to hydrogen ions. The product resulting from treatment with the fluid medium is an activated crystalline and/or amorphous aluminosilicate in which the nuclear structure thereof has been modified solely to the extent of having protons and metallic cations chemisorbed or ionically bonded thereto. The activated aluminosilicate contains at least 0.5 equivalent and preferably contains more than 0.9 equivalent of ions of positive valence per gram atom of aluminum. Except for alkali metal cations which may be present as impurities to the extent of less than 0.25 equivalent per gram atom of aluminum, no other cations of metals of Group I-A of the Periodic Table are associated with the aluminosilicate. When subsequently dried, washed or further used as an intermediate, this product has been found to be extremely active as a catalyst for hydrocarbon conversion.

In preparing the catalyst composition, the aluminosilicate can be contacted with a non-aqueous or aqueous fluid medium comprising a gas, polar solvent or water solution containing the desired hydrogen ion or ammonium ion capable of conversion to a hydrogen ion and at least one metallic salt soluble in the fluid medium. Alternatively, the aluminosilicate can be first contacted with a fluid medium containing a hydrogen ion or ammonium ion capable of conversion to a hydrogen ion and then with a fluid medium containing at least one metallic salt. Similarly, the aluminosilicate can be first contacted with a fluid medium containing at least one metallic salt and then with a fluid medium containing a hydrogen ion or an ion capable of conversion to a hydrogen ion or a mixture of both. Water is the preferred medium for reasons of economy and ease of preparation in large scale operations involving continuous or batchwise treatment. Similarly, for this reason, organic solvents are less preferred but can be employed providing the solvent permits ionization of the acid, ammonium compound and metallic salt. Typical solvents include cyclic and acyclic ethers such as dioxane, tetrahy drofuran, ethyl ether, diethyl ether, diisopropyl ether, and the like; ketones such as acetone and methyl ethyl ketone; esters such as ethyl acetate, propyl acetate; alcohols such as ethanol, propanol, butanol, etc.; and miscellaneous solvents such as dimethylformamide, and the like.

The hydrogen ion or ammonium ion may be present in the fluid medium in an amount varying within wide limits dependent upon the pH value of the fluid medium. Where the aluminosilicate material has a molar ratio of silica to alumina greater than about 5.0, the fluid medium may contain a hydrogen ion, metal cation, ammonium ion, or a mixture thereof, equivalent to a pH value ranging from less than 1.0 up to a pH value of about 12.0. Within these limits, pH values for fluid media containing a metallic cation and/or an ammonium ion range from 4.0 to 10.0, and are preferably between a pH value of 4.5 to 8.5. For fluid media containing a hydrogen ion alone or with a metallic cation, the pH values range from less than 1.0 up to about 7.0, and are preferably within the range of less than 1.0 up to 4.5. Where the molar ratio of the aluminosilicate is greater than about 2.2 and less than about 5.0, the pH value for the fluid media containing a hydrogen ion or a metal cation ranges from 3.8 to 8.5. Where ammonium ions are employed, either alone or in combination with metallic cations, the pH value ranges from 4.5 to 9.5 and is preferably within the limit of 4.5 to 8.5. When the aluminosilicate material has a molar ratio of silica to alumina less than about 3.0, the preferred medium is a fluid medium containing an ammonium ion instead of a hydrogen ion. Thus, depending upon the silica to alumina ratio, the pH value varies within rather wide limits. In such instances, where the fluid medium contains an acid and is unfavorable to the molecular structure of the aluminosilicate, a fluid medium may consist, for ex ample, of a vaporized ammonium compound such as am monium chloride, or an aqueous or non-aqueous medium containing the same. In this manner, aluminosilicates otherwise unsuitable for treatment with an acid-containing fluid medium are readily activated to provide useful catalyst compositions.

In carrying out the treatment with the fluid medium, the procedure employed comprises contacting the aluminosilicate with the desired fluid medium or media until such time as metallic cations originally present in the aluminosilicate are virtually exhausted. Cations of metals of Group I-A of the Periodic Table, if present in the modified aluminosilicate, tend to suppress or limit catalytic proper ties, the activity of which, as a general rule, decreases with increasing content of these metallic cations. Effective treatment with the fluid medium to obtain a modified aluminosilicate having high catalytic activity will vary, of course, with the duration of the treatment and temperature at which it is carried out. Elevated tempeartures tend to hasten the speed of treatment whereas the duration thereof varies inversely with the concentration of the ions in the fluid medium. In general, the temperatures employed range from below ambient room temperatures of 24 C. up to temperatures below the decomposition temperature of the aluminosilicate. Following the fluid treatment, the treated aluminosilicate is washed with water, preferably distilled Water, until the eflluent wash water has a pH value of wash water, i.e., between about 5 and 8. The aluminosilicate material is thereafter analyzed for metallic ion content by methods Well known in the art. Analysis also involves analyzing the effluent wash for anions obtained in the wash as a result of the treatment, as well as determination of the correction for anions that pass into the efiluent wash from soluble substances or decomposition products of insoluble substances which are otherwise present in the aluminosilicate as impurities.

The actual procedure employed for carrying out the fluid treatment of the aluminosilicate may be accomplished in a batchwise or continuous method under atmospheric, subatmospheric or superatmospheric pressure. A solution of the ions of positive valence in the form of a molten material, vapor, aqueous or non-aqueous solution, may be passed slowly through a fixed bed of the aluminosilicate. If desired, hydrothermal treatment or a corresponding non-aqueous treatment with polar solvents may be effected by introducing the aluminosilicate and fluid medium into a closed vessel maintained under autogenous pressure. Similarly, treatments involving fusion or vapor phase contact may be employed providing the melting point or vaporization temperature of the acid or ammonium compound is below the decomposition temperature of the aluminosilicate.

A wide variety of acidic compounds can be employed with facility as a source of hydrogen ions and include both inorganic and organic acids.

Representative inorganic acids which can be employed include acids such as hydrochloric acid hypochlorous acid, chloroplatinic acid, sulfuric acid, sulfurous acid, hydrosulfuric acid, peroxydisulfonic acid (H S O peroxymonosulfuric acid (H dithionic acid (P1 5 0 sulfamic acid (H NHS H), amidodisulfonic acid chlorosulfuric acid, thiocyanic acid, hyposulfurous acid (H S O pyrosulfuric acid (B 8 07), thiosulfuric acid (H S O nitrosulfonic acid (HSO -NO), hydroxyamine disulfonic acid ((HSO3)2NOH), nitric acid, nitrous acid, hyponitrous acid, carbonic acid and the like.

Typical organic acids which find utility in the practice of the invention include the monocarboxylic, dicarboxylic and polycarboxylic acids which can be aliphatic, aromatic or cycloaliphatic in nature.

Representative aliphatic monocarboxylic, dicarboxylic and polycarboxylic acids include the saturated and unsaturated, substituted and unsubstituted acids such as formic acid, acetic acid, chloroacetic acid, dichloroacetic acid, trichloroacetic acids, brornoacetic acid, propionic acid, Z-bromopropionic acid, 3-bromopropionic acid, lactic acid, n-butyric acid, isobutyric acid, crotonic acid, n-valeric acid, isovaleric acid, n-caproic acid, oenanthic acid, pelargonic acid, capric acid, undecylic acid, lauric acid, myristic acid, palmitic acid, stearic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, alkylsuccinic acid, alkenylsuccinic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid, mesaconic acid, glutonic acid, muconic acid, ethylidene malonic acid, isopropylidene malonic acid, allyl malonic acid.

Representative aromatic and cycloaliphatic monocarboxylic, dicarboxylic and polycarboxylic acid include l,2-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, 2-carboxy-2-methylcyclohexaneacetic acid, phthalic acid, isophthalic acid, terephthalic acid, 1,8-naphthalenedicarboxylic acid, l,2-naphthalenedicarboxylic acid, tetrahydrophthalic acid, 3-carboxy-cinnamic acid, hydrocinnamic acid, pyrogallic acid, benzoic acid, ortho, meta and paramethyl, hydroxy, chloro, bromo and nitrosubstituted benzoic acids, phenylacetic acid, mandelic acid, benzylic acid, hippuric acid, benzenesulfonic acid, toluenesulfonic acid, methanesulfonic acid and the like.

Other sources of hydrogen ions include carboxy polyesters prepared by the reaction of an excess polycarboxylic acid or an anhydride thereof and a polyhydric alcohol to provide pendant carboxyl groups.

Still other materials capable of providing hydrogen ions are ion exchange resins having exchangeable hydrogen ions attached to base resins comprising cross-linked resinous polymers of monovinyl aromatic monomers and polyvinyl compounds. These resins are well known materials which are generally prepared by copolymerizing in the presence of a polymerization catalyst one or more monovinyl aromatic compounds, such as styrene, vinyl toluene, vinyl xylene, with one or more divinyl aromatic compounds such as divinyl benzene, divinyl toluene, divinyl xylene, divinyl naphthalene and divinyl acetylene. Following copolymerization, the resins are further treated with suitable acids to provide the hydrogen form of the resin.

Still another class of compounds which can be employed are ammonium compounds which decompose to provide hydrogen ions when an aluminosilicate treated with a solution of said ammonium compound is subjected to temperatures below the decomposition temperature of the aluminosilicate.

Representative ammonium compounds which can be employed include ammonium chloride, ammonium bromide, ammonium iodide, ammonium carbonate, ammo nium bicarbonate, ammonium sulfate, ammonium sulfide, ammonium thiocyanate, ammonium dithiocarbamate, ammonium peroxysulfate, ammonium acetate, ammonium tungstate, ammonium hydroxide, ammonium molybdate, ammonium benzoate, ammonium borate, ammonium carbamate, ammonium sesquicarbonate, ammonium chloroplumbate, ammonium citrate, ammonium dithionate, ammonium fluoride, ammonium gallate, ammonium nitrate, ammonium nitrite, ammonium formate, ammonium propionate, ammonium butyrate, ammonium valerate, ammonium lactate, ammonium malon-ate, ammonium oxalate, ammonium palmitate, ammonium tartarate and the like. Still other ammonium compounds which can be employed include tetraalkyl and tetraaryl ammonium salts such as tetramethylammonium hydroxide, trimethylammonium hydroxide. Other compounds which can be employed are nitrogen bases such as the salts of guanidine, pyridine, quinoline, etc.

A wide variety of metallic compounds can be employed with facility as a source of metallic cations and include both inorganic and organic salt of the metals of Group I-B through Group VIII of the Periodic Table.

Representative of the salts which can be employed include chlorides, bromides, iodides, carbonates, bicarbonates, sulfates, sulfides, thiocyanates, dithiocarbamates, peroxysulfates, acetates, benzoate citrates, fluorides, nitrates, nitrites, formates, propionates, butyrates, valerates, lactates, malonates, oxalates, palmitates, hydroxides, tartarates and the like. The only limitations on the par ticular metal salt or salt employed are that it be soluble in the fluid medium in which it is used and compatible with the hydrogen ion source, especially if both the metallic salt and the hydrogen ion source are in the same fluid medium. The preferred salts are the chlorides, nitrates, acetates and sulfates.

Of the wide variety of metallic salts which can be employed, the most preferred are salts of trivalent metals, then of divalent metals and lastly, of monovalent metals. Of the divalent metals, the preferred ones are of Group II-A of the Periodic Table. The particularly preferred salts are those of the rare earth metals including cerium, lanthanum, praseodymium, neodymium, illinium, samortium, europium, galodolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium and lutecium.

The rare earth salts employed can either be the salt of a single metal or preferably, of mixtures of metals such as a rare earth chloride or didymium chlorides. As hereinafter referred to, a rare earth chloride solution is a mixture of rare earth chlorides consisting essentially of the chlorides of lanthanum, cerium, neodymium and praseodymium with minor amounts of samarium, gadolinium and yttrium. The rare earth chloride solution is commercially available and it contains the chlorides of a rare earth mixture having the relative composition cerium (a CeO 48% by weight, lanthanum (as La O 24% by weight, praseodymium (as Pr O 5% by weight, neodymium (as Nd O 17% by weight, samarium (as Sm O 3% by weight, gadolinium (as Gd O 2% by weight, yttrium (as Y O 0.2% by weight and other rare earth oxides 0.8% by weight. Didymium chloride is also a mixture of rare earth chlorides, but having a low cerium content. It consists of the following rare earths determined as. oxides: lanthanum, 45-46% by weight; cerium 12% by weight; praseodymium, 9-10% by weight; neodymium, 32-33% by weight; samarium, 56% by weight; gadolinium 3-4% by weight; yttrium 0.4% by weight; other rare earths 12% by weight. It is to be understood that other mixtures of rare earths are equally applicable in the instant invention.

Representative metal salts which can be employed, aside from the mixtures mentionel above, include silver chloride, silver sulfate, silver nitrate, silver acetate, silver arsenate, silver bromide, silver citrate, silver carbonate, silver oxide, silver tartrate, calcium acetate, calcium arsenate, calcium benzoate, calcium bromide, calcium carbonate, calcium chloride, calcium citrate, beryllium bromide, beryllium carbonate, beryllium hydroxide, beryllium sulfate, barium acetate, barium bromide, barium carbonate, barium citrate, barium malonate, barium nitrite, barium oxide, barium sulfide, magnesium chloride, magnesium bromide, magnesium sulfate, magnesium sulfide, magnesium acetate, magnesium formate, magnesium stearate, magnesium tartrate, zinc sulfate, zinc nitrate, zinc acetate, zinc chloride, zinc bromide, aluminum chloride, aluminum bromide, aluminum acetate, aluminum citrate, aluminum nitrate, aluminum oxide, aluminum phosphate, aluminum sulfate, titanium bromide, titanium chloride, titanium nitrate, titanium sulfate, zirconium chloride, zirconium nitrate, zirconium sulfate, chromic acetate, chromic chloride, chromic nitrate, chromic sulfate, ferric chloride, ferric bromide, ferric acetate, ferrous chloride, ferrous arsenate, ferrous lactate, ferrous sulfate, nickel chloride, nickel bromide, cerous acetate, cerous bromide, cerous carbonate, cerous chloride, cerous iodide, cerous sulfate, cerous sulfide, lanthanum chloride, lanthanum bromide, lanthanum nitrate, lanthanum sulfate, lanthanum sulfide, yttrium bromate, yttrium bromide, yttrium chloride, yttrium nitrate, yttrium sul fate, samarium acetate, samarium chloride, samarium bromide, samarium sulfate, neodymium chloride, neodymium oxide, neodymium sulfide, neodymium sulfate, praseodymium chloride, praseodymium bromide, praseodymium sulfate, praseodymium sulfide, etc.

The aluminosilicates treated in accordance with the invention include a wide variety of aluminosilicates, both natural and synthetic, which have an amorphous or preferably either a crystalline structure or a combination of crystalline and amorphous. These aluminosilicates can be described as a three dimensional framework of SiO, and A10 tetrahedra in which the tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total aluminum and silicon atoms to oxygen atoms is 1:2. In their hydrated form the aluminosilicates may be represented by the formula:

wherein M is a cation which balances the electrovalence of the tetrahedra, n represents the valence of the cation, w the moles of SiO and y the moles of H 0. The cation can be any or more of a number of metal ions depending on whether the aluminosilicate is synthesized or occurs naturally. Typical cations include sodium, lithium, potassium, silver, magnesium, calcium, zinc, barium, iron and manganese. Although the proportions of inorganic oxides in the silicates and their spatial arrangement may vary, effecting distinct properties in the aluminosilicates, the two main characteristics of these materials is the presence in their molecular structure of at least 0.5 equivalent of an ion of positive valence per gram atom of aluminum, and an ability to undergo dehydration without substantially affecting the SiO, and A10 framework. In this respect, these characteristics are essential for obtaining catalyst compositions of high activity in accordance with the invention.

Representative materials include synthesized crystalline aluminosilicates, designated Zeolite X, which can be represented in terms of mole ratios of oxides as follows:

wherein M is a cation having a valence of not more than three, n represents the valence of M, and y is a value up to eight depending on the identity of M and degree of hydration of the crystal. The sodium form may be represented in terms of mole ratios of oxides as follows:

0.9N3-201A1203I2.5SIO216.1H2O

Another synthesized crystalline aluminosilicate, designated Zeolite A, can be represented in mole ratios of oxides as:

wherein M represents a metal, n is the valence of M, and y is any value up to :about 6. As prepared, Zeolite A contains primarily sodium cations and is designated sodium Zeolite A.

Other suitable synthesized crystalline aluminosilicates are those designated Zeolite Y, L and D.

The formula for Zeolite Y expressed in oxide mole wherein w is a value ranging from 3 to 6 and y may be any value up to about 9.

The composition of Zeolite L in oxide mole ratios may be represented as:

wherein M designates a metal, n represents the valence of M, and y is any value from O to 7.

The formula for Zeolite D, in terms of oxide mole ratios, may be represented as:

wherein w is from 2.45 to 3.65, and y, in the hydrated form, is about 7.

The formula for Zeolite S in terms of oxide mole ratios may be written as:

wherein w is from 4.6 to 5.9 and y, in the hydrated form, is about 6 to 7.

The formula for Zeolite T in terms of oxide mole ratios may be written as:

wherein x is any value from about 0.1 to about 0.8, and y is any value from about to about 8.

The formula for Zeolite Z in terms of oxide mole ratios may be written as:

K20 IAI203I2SIO2IYH2O wherein y is any value not exceeding 3.

The formula for Zeolite E in terms of oxide mole ratios may be written as:

wherein M is a cation, n is the valence of the cation, and y is a value of 0 to 4.

. The formula for Zeolite F in terms of oxide mole ratios may be written as:

0.951-015 M O:Al O :2.05i0.3 SiO Iy H O (XIII) wherein M is a cation, 11 is the valence of the cation, and y is any value from 0 to about 3.

The formula for Zeolite Q, expressed in terms of oxide mole atios may be written as:

0.95:0.05 M O:Al O :2.2:t0.05 SiO Iy H O (XIV) wherein M is a cation, n is the valence of the cation, and

y is any value from 0 to 5.

The formula for Zeolite B may be written in terms of oxide mole ratios as:

1.0:01 M O:Al O :3.5i1.5 SiO :y H2O xv wherein M represents a cation, n is the valence of the cation, and y has an average value of 5.1 but may range from 0 to 6.

Other synthesized crystalline aluminosilicates include those designated as ZK-4 and ZK-S.

ZK-4 can be represented in terms of mole ratios of oxides as:

0.1 to 0.3R:0.7 to 1.0 M OIAl O Z 2.5 to 4.0 S iO :y H O (XVI) wherein R is a member selected from the group consisting of methylammonium oxide, hydrogen'oxide and mixtures thereof with one another, M is a metal cation having a valence of n and y is any value from about 3.5 to about 5.5. As synthesized, Zeolite ZK-4 contains primarily sodium cations and can be represented by unit cell formula:

The major lines of the X-ray diffraction patern of ZK-4 are set forth in Table 1 below:

TABLE 1 d Value of reflection in A.: 1/1 12.00 100 ZK-4 can be prepared by preparing an aqueous solution of oxides containing as Na O, A1 03, SiO H 0 and tetramethylammonium ion having a composition, in terms of oxide mole ratios, which falls within the following ranges:

maintaining the mixture at a temperature of about 100 C. to 120C. until the crystals are formed, and separating the crystals from the mother liquor. The crystal material is thereafter washed until the wash efliuent has a pH essentially that of wash water and subsequently dried.

ZK-S is representative of another crystalline aluminosilicate which is prepared in the same manner as Zeolite ZK-4 except that N,N'-dimethyltriethylenediammonium hydroxide is used in place of tetramethylammonium hydroxide. ZK-5 may be prepared from an aqueous sodium aluminosilicate mixture having the following composition expressed in terms of oxide mole ratios as:

The N,N-dimethyltriethylenediammonium hydroxide used in preparing ZK-S can be prepared by methylating 1,4-diazobicyclo-(2.2.2)-octane with methyl iodide or dimethyl sulfate, followed by conversion to the hydroxide by treatment with silver oxide or barium hydroxide. The reaction may be illustrated as follows:

In using the N,N'-dimethyltriethylene-diammonium hydroxide compound in the preparation of ZK-S, the hydroxide may be employed per se, or further treated with a source of silica, such as silica gel, and thereafter reacted with aqueous sodium aluminate in a reaction mixture whose chemical composition corresponds to the above-noted oxide mole ratios. Upon heating at temperatures of about 200 to 600 C., the methyl ammonium ion is converted to hydrogen ion.

Among the naturally occurring crystalline aluminosilicates which can be employed for purposes of the invention are included levynite, dachiardite, erionite, faujasite, analcite, paulingite, noselite, ferriorite, heulandite, scolecite, stilbite, clinoptilolite, harmotome, phillipsite, brewsterite, flakite, datolite, and aluminosilicates represented as follows:

chabaziteNa O.Al O .4'SiO .6H O gmelinite-Na .Al O .4SiO .6H O cancrinite3 (Na O.Al O .2SiO .Na CO leuciteK O.Al O lazurite(Na,Ca) Al Si O 4.2 (S,Cl,SO scapoliteNa Al Si 0 .01 meSOlite Na2O .Al2 O3 3 Slog. H2O ptilolite-Na O.Al O .1OSiO .4H O mordenite-Na O Al O l 0SiO .6.6H O nephelineNa O.Al O .2SiO natroliteNa O.Al O .3SiO .2H O sodalite3 (Na O.Al O .2SiO .ZNaCl Other aluminosilicates which can be used are caustic treated clays.

Of the clay materials, montmorillonite and kaolin families are representative types which include the sub-bentonites, such as bentonite, and the kaolins commonly identified as Dixie, McNamee, Georgia and Florida clays in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite, or anauxite. Such clays may be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. In order to render the clays suitable for use, however, the clay material is treated with sodium hydroxide or potassium hydroxide, preferably in admixture with a source of silica, such as sand, silica gel or sodium silicate, and calcined at temperatures ranging from 230 F. to 1600 F. Following calcination, the fused material is crushed, dispersed in water and digested in the resulting alkaline solution. During the digestion, materials with varying degrees of crystallinity are crystallized out of solution. The solid material is separated from the alkaline material and thereafter washed and dried. The treatment can be effected by reacting mixtures falling within the following weight ratios:

Na O/clay (dry basis)-l.06.6 to 1 SiO /clay (dry basis)-0.0l3.7 to 1 H O/Na O (mole rati0)35180 to 1 As previously noted, the active aluminosilicates used for purposes of the invention are characterized as having at least 0.5 equivalent of an ion of positive valence per gram atom of aluminum as determined by base exchanging with other cations by recognized techniques. Aluminosilicate starting materials not possessing this characteristic, however, may be employed providing they are either pretreated or acquire this characteristic as a result of treatment with the fluid medium. As an example of pretreatment, argillaceous materials contacted with caustic or caustic-silica mixtures, as above-described, results in the formation of amorphous and/or crystalline aluminosilicates having at least 0.5 equivalent, usually about 1.0 equivalent, of cation per gram atom of aluminum.

As has heretofore been pointed out, the novel compositions of this invention are aluminosilicates containing from 0.5 to 1.0 equivalent per gram atom of aluminum of ions of positive valence, said ions being from 0.01 to 0.99 equivalent per gram atom of aluminum of hydrogen ion and from 0.99 to 0.01 equivalent per gram atom of aluminum of at least one cation of metals selected from Groups I-B through VIII of the Periodic Table. Except for alkali metal cations which may be present as impurities to the extent of less than 0.25 equivalent per gram atom of aluminum, no cations of metals of Group I-A of the Periodic Table are associated with the aluminosilicate.

Within the above limits of the novel aluminosilicates of this invention, it is preferred that there be no alkali metal associated with the aluminosilicates, since the presence of these metals tends to suppress or limit catalytic properties, the activity of which, as a general rule, de-

creases With increasing content of alkali metal cations. It,

is also preferred that the novel aluminosilicates have between 0.8 and 1.0, more preferably 1.0, equivalent per gram atom of aluminum of the ions of positive valence previously set forth.

Additionally, it is preferred that the metal cation or cations be present in an amount from 40-85% of the total equivalent of ions of positive valence contained in the novel aluminosilicates of the instant invention. More preferably, the metal cation or cations should be present in an amount from 50-75% with from 75-85% being particularly preferred.

Therefore, the most preferred embodiment of this invention is an aluminosilicate containing 1 equivalent of ions of positive valence, said ions consisting of hydrogen ions and from 0.75 to 0.85 equivalent of cations of at least one rare earth metal.

The catalysts of this invention may be used in powdered, granular or.molded state formed into spheres or pellets of finely divided particles having a particle size of 2 to 500 mesh. In cases where the catalyst is molded, such as byv extrusion, the aluminosilicate may be extruded before drying, or dried or partially dried and then extruded. The catalyst product is then preferably precalcined in an inert atmosphere near the temperature contemplated for conversion but may be calcined initially during use in the conversion process. Generally, the aluminosilicate is dried between 150 F. and 600 F. and thereafter calcined in air or an inert atmosphere of nitrogen, hydrogen, helium, flue gas or other inert gas at temperatures ranging from about 500 F. to 1500 F. for periods of time ranging from 1 to 48 hours or more.

It has been further found in accordance with the invention that catalysts of improved activity and having other beneficial properties in the conversion of hydrocarbons are obtained by subjecting the treated aluminosilicate to a mild steam treatment carried out at elevated temperatures of 800 F. to 1500 F., and preferably at temperatures of about 100 F. to 1300 F. The treatment may be accomplished in an atmosphere of 100 percent steam or in an atmosphere consisting of steam and a gas which is substantially inert to the aluminosilicate. The steam treatment apparently provides beneficial properties in the aluminosilicate.

The high catalytic activities obtained by aluminosilicate compositions prepared in accordance with the invention are illustrated in connection with the cracking of a representative hydrocarbon charge. In the examples hereinafter set forth, the reference catalyst employed consisted of a conventional silica-alumina bead" type cracking catalyst. The silica-alumina catalyst contained about weight percent Al O and the remainder SiO In some instances it also contained a trace amount of Cr O i.e., about 0.15 weight percent.

The cracking activity of the catalyst is further illustrated by its ability to catalyze the conversion of a Mid- Continent Gas Oil having a boiling range of 450'950 F. to gasoline having an end point of 410 F. Vapors of the gas oil are passed through the catalyst at temperatures of 875 F. or 900 F. substantially at atmospheric pressure at a feed rate of 1.5 to 16.0 volumes of liquid oil per volume of catalyst per hour for ten minutes. The method of measuring the instant catalyst was to compare the various product yields obtained with such catalyst with yields of'the same products given by conventional silica-alumina catalyst at the same conversion level. The differences (A values) shown hereinafter represent the yields given by the present catalyst minus yields given by the conventional catalyst. In these tests the catalyst composition of the invention was precalcined at about 1000 F. prior to their evaluation as a cracking catalyst.

The catalysts prepared in accordance with the invention find extensive utility in a wide variety of hydrocarbon conversion processes including the dehydrogenation of dehydrogenatable organic compounds, the dehydrocyclization of parafiin hydrocarbons having six or more carbon atoms, the desulfurization of sulfur-bearing hydrocarbon fractions, the oxidation of organic compounds, the hydrogenation of organic compounds, the dehydration of alcohols, alkylation of aromatic or isoparaflinic hydrocarbons with olefinic hydrocarbons, alcohols, esters, etc., and polymerization of unsaturated hydrocarbons to form higher boiling products, etc.

The following examples illustrate the best mode now contemplated for carrying out the invention.

EXAMPLE 1 A synthetic crystalline aluminosilicate identified as Zeolite 13X was subjected to 12 two-hour treatments at 180 F. with an aqueous solution containing 5% by weight mixture of rare earth chlorides and 2% by weight of ammonium chloride. The alumino-silicate was then washed with water until there were no chloride ions in the effluent, dried, and then treated for 20 hours at 1225 F. with atmospheric steam to yield a catalyst having a sodium content of 0.31 weight percent.

The following table shows the cracking data obtained when the catalyst was evaluated for cracking gas oil at 900 F.

TABLE 1 Cracking data Conversion, vol. percent 60.9 LI-ISV 16 10 RVP gaso., vol. percent 54.6 Excess C s, vol. percent 9.5 0 gasoline, vol. percent 51.7 Total C s, vol. percent 12.5 Dry gas, wt. percent 5.6 Coke, wt. percent 2.3 H wt. percent 0.02

A Advantage 10 RVP, vol. percent +9.3

Excess C s, vol. percent 4.5 C +Gasoline, vol. percent +7.4 Total C s, vol. percent 3.7 Dry gas, wt. percent 2.2 Coke, wt. percent 2.4

EXAMPLE 2 The procedure of Example 1 was repeated with the exception that the crystalline aluminosilicate was subjected to a continuous treatment for 24 hours instead of 12 twohour treatments. The following table shows the cracking data obtained when the catalyst was evaluated for cracking gas oil at 900 F.

TABLE 2 Cracking data Conversion, vol. percent 60.7 LSHV 16 10 RVP gaso., vol. percent 51.7 Excess C s, vol. percent 11.2 C +gasoline, vol. percent 49.2 Total C s, vol. percent 13.7 Dry gas, wt. percent 6.4 Coke, wt. percent 3.0 H wt. percent 0.03

A Advantage 10 RVP gaso., vol. percent +6.5 Excess C s, vol. percent 2.8 C gasoline, vol. percent +6.2 Total C s, vol. percent 2.5 Dry gas, wt. percent -l.3 Coke, wt. percent -1.7

EXAMPLE 3 A crystalline aluminosilicate identified as Zeolite 13X was subjected to three 2-hour treatments with a 5% 'by weight aqueous solution of ammonium chloride and then treated for 48 hours with an aqueous solution eonsist- EXAMPLE 4 A synthetic crystalline aluminosilicate identified as Zeolite 13X was treated for 72 continuous hours with an aqueous soluction containing 10% by weight of ammonium chloride, 10% by weight of ammonium acetate, and 1% by weight of rare earth chlorides. The aluminosilicate was then Washed with water until there were no chloride or acetate ions in the efiluent, dried and then treated for 24 hours at 1200" F. with stream at a pressure of 15 p.s.1.g.

The following table shows the cracking data obtained when the catalyst was evaluated for cracking gas oil at 900 F.

TABLE 3 Cracking data Conversion, vol. percent 56.6 LHSV 16.0 10 RVP gaso., vol. percent 50.9 Excess C s, vol. percent 9.2 C +gasoline, vol. percent 48.3 Total C s, vol. percent 11.8 Dry gas, wt. percent 5.4 Coke, wt. percent 1.4 H wt. percent 0.01

A Advantage RVP gaso., vol. percent +7.9

Excess C s, vol. percent +3.4 C +gasoline, vol. percent +7.4 Total C s, vol. percent 3.0 Dry gas, wt. percent +1.6 Coke, wt. percent -2.5

EXAMPLE 5 A synthetic crystalline aluminosilicate identified as Zeolite 13X was subjected to 24 two-hour treatments with an aqueous solution consisting of 5% by weight of lanthanum chloride and 2% by weight of ammonium chloride at 180 F. The aluminosilicate was then washed with water until there were no chloride ions in the eflluent, dried and then treated for 20 hours at 1225 F. with 100% atmospheric steam to yield a catalyst having a sodium content of 0.36 weight percent.

The following table shows the cracking data obtained when the catalyst was evaluated for cracking gas oil at 900 F.

TABLE 4 Cracking data Conversion, vol. percent 63.1 LHSV 16 10 RVP gaso., =vo1. percent 52.6 Excess C s, vol. percent 12.3 C +gasoline, vol. percent 50.4 Total C s, vol. percent 14.5 Dry gas, wt. percent 6.8 Coke, wt. percent 3.6 H wt. percent 0.04

A Advantage 10 RVP, vol. percent +6.2 Excess C s, vol. percent 2.7 C +gasoline, vol. percent +6.2 Total C s, vol. percennt 2.5 Dry gas, wt. percent --1.4

Coke, wt. percent -1.5

EXAMPLE 6 The procedure of Example 5 was repeated with the exception that the aluminosilicate was steamed for 24 hours at 1200 F. with steam at 15 p.s.i.g. The cracking data obtained when using this catalyst for cracking gas oil at 900 F., is shown in the following table.

TABLE 5 Cracking data Conversion, vol. percent "65.9 LHSV 16 10 RVP gaso., vol. percent 56.5 Excess C s, vol. percent 12.1 C +gasoline, vol. percent 53.9 Total C s, vol. percent 14.7 Dry gas, wt. percent 6.6 Coke, wt. percent 3.0 H wt. percent 0.03

A Advantage 10 RVP, vol. percent +8.8 Excess C s, vol. percent 3.9 C +gasoline, vol. percent +8.4 Total C s, vol. percent 3.3 Dry gas, wt. percent -2.1 Coke, wt. percent +2.7

EXAMPLE 7 The procedure of Example 6 was repeated with the exception that 36 two-hour contacts of the lanthanum chloride and ammonium chloride solution were employed instead of 24 two-hour contacts. The resulting catalyst had a sodium content of 0.46 weight percent. Table 6 shows the cracking data obtained when the catalyst was evaluated for cracking gas oil at 900 F.

TABLE 6 Cracking data EXAMPLE 8 A synthetic crystalline aluminosilicate identified as Zeolite 13X was treated with an aqueous solution containing 2% by weight mixture of rare earth chlorides for 18 continuous hours and then treated with an aqueous solution of ammonium sulfate containing 5% by weight of ammonium sulfate for 3 contacts of 16 hours each and then with 9 contacts of 2 hours each of the same solution. The treated aluminosilicate was washed with water until the eflluent contained no chloride or sulfate ions, dried and then treated for 30 hours at 1200 F. with steam at 15 p.s.i.g. The resulting catalyst contained 0.12 weight percent sodium. The catalytic evaluation of the aluminosilicate for cracking gas oil at 900 F. is shown in the following table.

15 TABLE 7 Cracking Data Conversion, vol. percent 37.5 LHSV 4 10 RVP gaso., vol. percent 32.5 Excess C s, vol. percent 6.5 C +gasoline, vol. percent 30.9 Total C s, vol. percent 8.1 Dry gas, wt. percent 4.1 Coke, wt. percent 1.4 H wt. percent 0.02

A Advantage RVP, vol. percent +0.1 Excess C s, vol. percent +0.5 C +gaso1ine, vol. percent +0.9 Total C s, vol. percent 1.4 Dry gas, wt. percent +0.1 Coke, wt. percent -O.2

EXAMPLE 9 A synthetic crystalline aluminosilicate identified as Zeolite Y was treated with an aqueous solution consisting of 5% by weight mixture of rare earth chlorides and 2% by weight of ammonium chloride and then washed with water until the effluent contained no chloride ions, dried and then treated for 24 hours at 1200 F. with p.s.i.g. steam. The resulting aluminosilicate contained 0.52 weight percent sodium and gave the following results when tested for cracking gas oil at 900 F.

TABLE 8 Cracking Data Conversion, vol. percent 16.6 LHSV 16 10 RVP gaso., vol. percent 54.9 Excess C s, vol. percent 9.8 C +gasoline, vol. percent 52.1 Total C s, vol. percent 12.5 Dry gas, wt. percent 6.1 Coke, wt. percent 1.9 H wt. percent 0.02

A Advantage 10 RVP, vol. percent +9.0 Excess C s, vol. percent 4.6 C +gasoline, vol. percent +8.6 Total C s, vol. percent +4.1 Dry gas, wt. percent +1.8 Coke, wt. percent 2.9

EXAMPLE 10 The procedure of Example 9 was repeated with the exception that the solution consisted of 5% by weight of calcium chloride and 2% by Weight of ammonium chloride. The catalytic evaluation for cracking gas oil at 900 F. is shown in the following table.

TABLE 9 Cracking Data Conversion, vol. percent 61.8 LHSV 10 10 RVP gaso., vol. percent 57.0 Excess C s, vol. percent 9.5 C +gasoline, vol. percent 54.0 Total C s, vol. percent 12.5 Dry gas, wt. percent 4.8 Coke, wt. percent 1.5 H wt. percent 0.01

A Advantage 10 RVP, vol. percent +11.2 Excess C s, vol. percent --4.9

C +gasoline, vol. percent +104 1 6 Total C s, vol. percent 4.1 Dry gas, wt. percent 3.2 Coke, wt. percent 3.3

EXAMPLE 11 The procedure of Example 9 was repeated with the exception that the treatment solution consisted of 5% by weight of lanthanum chloride and 2% by weight of ammonium chloride. The catalytic evaluation for cracking gas oil at 900 F. is shown in the following table:

TABLE 10 Cracking Data Conversion, vol. percent 66.1 LHSV 16 10 RVP gaso., vol. percent 59.0 Excess C s, vol. percent 9.3 C +gasoline, vol. percent 55.7 Total C s, vol. percent 12.6 Dry gas, wt. percent 7.0 Coke, wt. percent 2.3 H wt. percent 0.02

A Advantage 10 RVP, vol. percent +11.2 Excess C s, vol. percent +6.9 C +gasoline, vol. percent +10.1 Total C s, vol. percent -5.7 Dry gas, wt. percent l.7 Coke, wt. percent -3.4

EXAMPLE 12 A synthetic crystalline aluminosilicate was prepared by mixing the following solutions:

(A) Sodium silicate solution Lbs. N-Brand sodium silicate 1 77.5 NaOH pellets 11.0 Water 143.0

Specific gravity, 1.172 at 68 F.

{8.8 Weight percent NazO, 28.5 weight percent SiOz, 62.7 weight percent water.

(B) Sodium aluminate solution Lbs. Sodium aluminate 25.6 Sodium hydroxide pellets 11.0

Water 195.0 Specific gravity, 1.140 at 68 F.

Solution (B) was added to solution (A) while agitating vigorously to break up the hydrogel as it formed into a creamy slurry. The slurry was heated for 12 hours at 205 F., filtered, washed to 11 pH and then dried in air at 280 F. to yield a crystalline aluminosilicate.

3.3 pounds of the aluminosilicate was treated with 4 batches of a 27.5% by weight aqueous solution of calcium chloride, each bath having 1 lb. of calcium chloride per pound of aluminosilicate. Three treatments were for 24 hours each at 180 F. and the fourth one was for 72 hours at room temperature. After the four treatments with the calcium chloride solution, the aluminosilicate was further treated four times with an aqueous solution containing 2% by weight of calcium chloride and 1% by weight of aluminium chloride for 4 contacts, 3 of which were for 2 hours and 1 was overnight, all 4 contacts being at room temperature. The aluminosilicate was then washed with water until the effluent contained no chloride ions, dried, pelleted to /2" size, ground to mesh and calcined for 10 hours in air at 1000 F. The aluminosilicate catalyst was then treated with steam at 1225 F. for 20 hours at atmospheric pressure. The resulting catalyst was evaluated for cracking gas oil at 875 F. and gave the following results.

A synthetic crystalline aluminosilicate identified as Zeolite 4A was treated three times for 24 hours and one time for 72 hours with a 26 weight percent aqueous solution of calcium chloride at 180 F. After the treatment with calcium chloride, the aluminosilicate was then treated for three two-hour contacts and one overnight con tact at room temperature with an aqueous solution consisting of 2% by weight of calcium chloride and 1% by weight ammonium chloride. The aluminosilicate was then washed with water until the efiluent contained no chloride ions, dried, calcined for 10 hours at 1000 F. in air, and then treated with steam for 20 hours at 1225 F. to yield a catalyst having a sodium content of 0.6 percent by weight.

EXAMPLE 14 A synthetic crystalline aluminosilicate identified as Zeolite A was treated with a chloroplatinic acid solution containing 2.0 grams platinum and an ammonium hydroxide solution containing 28% by weight ammonia. The aluminosilicate was washed with water until the efliuent contained no chloride ions, dried and then treated for 20 hours at 1225 F. with atmospheric steam to yield an aluminosilicate having excellent catalyst properties.

EXAMPLE 15 1800 grams of a crystalline aluminosilicate identified as Zeolite 13X was treated with a solution consisting of cerium chloride and ammonium hydroxide. The treatment was carried out at a temperature of 160-180 F. for /2 hour after which time the slurry was filtered and then the operation repeated for another /2 hour. The resulting aluminosilicate contained 0.81 weight percent sodium and 24.7 weight percent cerium.

EXAMPLE 16 66.5 grams of a synthetic crystalline aluminosilicate identified as Zeolite 5A was pelleted and treated with 26.6 grams of ammonium nitrate dissolved in 1 gallon of distilled water. The product was rinsed with distilled water until the effiuent contained no nitrate ions and then calcined at 650700 F. for several hours in a stream of nitrogen. The resulting aluminosilicate analyzed at 9.08 weight percent calcium.

EXAMPLE 17 A natural crystalline aluminosilicate identified as Gmelinite was crushed to a particle size of less than 32 mesh and calcined in air for 2 hours at 650 F. 5 grams of the calcined crushed Gmelinite was treated times with 10 cc. of a solution containing 4% by weight mixture of rare earth chlorides and 1% by weight ammonium chloride. Each of the treatments was for 1 hour at a temperature of 173186 F. The aluminnosilicate was then washed with water until the effluent contained no chloride ions, dried overnight at 190 F., pelleted, recrushed to a particle size of less than 12 mesh and calcined for three hours at 900 F. in air. The resulting product was employed as a catalyst for the cracking of decane 18 at a catalyst concentration of 3.3 cc. at a feed rate of 3.0 LHSV, and temperature of 900 F. A conversion of 91.6% by weight was obtained.

EXAMPLE 18 The procedure of Example 17 was repeated with the exception that Ptilolite was employed instead of Gmelinite. When the resulting catalyst was used to crack decane, it gave a conversion of 58.7% by weight.

EXAMPLE 19 The procedure of Example 17 was repeated with the exception that the aluminosilicate employed was identified as Chabazite. The resulting catalyst gave a conversion of by weight when employed to crack decane.

EXAMPLE 20 A synthetic crystalline aluminosilicate, identified as Zeolite 13X, was subjected to 12 two-hour treatments at F. with an aqueous solution containing 5% by weight mixture of rare earth chlorides and 2% by weight of ammonium chloride. The aluminosilicate was then treated with a 10% by weight aqueous solution of ammonium carbonate for 4 hours at 180 F. The resulting modified aluminosilicate was then washed with water until there were no chloride or carbonate ions in the efiluent, dried and then treated for 24 hours at 1200 F. with steam at 15 p.s.i.g. to yield a catalyst having a sodium content of 0.65 weight percent.

The following table shows the cracking data obtained when the catalyst was evaluated for cracking gas oil at 900 F.

TABLE 12 Cracking data Conversion, vol. percent 43.4 LHSV 8 10 RVP, gaso., vol. percent 40.9 Excess C s, vol. percent 5.8 C +gasoline, vol. percent 38.6 Total C s, vol. percent 8.2 Dry gas, wt. percent 3.6 Coke, wt. percent 0.9 H wt. percent 0.02

A Advantage 10 RVP, vol. percent +5.1 Excess, C s, vol. percent 2.9 C +gasoline, vol. percent +5.1 Total C s, vol. percent 2.8 Dry gas, wt. percent 1.3 Coke, wt. percent 1.l2

EXAMPLE 21 The procedure of Example 20 was repeated with the exception that a 10% by weight aqueous solution of ammonium phosphate was employed instead of the ammo nium carbonate. The resulting catalyst had a sodium content of 0.5 weight percent and the cracking data shown in the following table when used at 900 C.

TABLE 13 Cracking data Conversion, vol. percent 42.2 LHSV 16 10 RVP, gaso., vol. percent 35.1 Excess C s, vol. percent 7.7 C +gasoline, vol. percent 33.5 Total C s, vol. percent 9.3 Dry gas, wt. percent 4.7 Coke, wt. percent 2.1

H wt. percent 0.02

The following examples illustrate the use of clays which have been treated with caustic in admixture with a source of silica, such as sand, silica gel or sodium silicate, calcined at temperatures ranging from 350 F. to 1600 F. crushed, dispersed in water and digested.

EXAMPLE 22 -McNamee clay, an aluminosilicate which had been caustic treated, was subjected to treatment with an aqueous solution consisting of by weight mixture of rare earth chlorides and 2%, by weight ammonium chloride. The aluminosilicate was then washed with water until the efiluent contained no chloride ions and treated for 20 hours at 1225 F. with steam at atmospheric pressure. The resulting alurninosilicate was evaluated for cracking gas oil at 900 and gave the following results.

TABLE 14 Cracking data Conversion, vol. percent 57.2 LHSV 16 RVP gaso., vol. percent 49.9 Excess C s, vol. percent 9.5 C +gasoline, vol. percent 47.4 Total C s, vol. percent 12.0 Dry gas, wt. percent 5.6 Coke, wt. percent 2.8 H wt. percent 0.05

A Advantage 10 RVP, vol. percent +6.5 Excess C s, vol. percent -3.2 C +gasoline, vol. percent +6.2 Total C s, vol. percent 3.0 Dry gas, wt. percent 1.6 Coke, wt. percent 1.2

EXAMPLE 23 Dixie clay, an aluminosilicate which had been caustic treated, was treated with an aqueous solution consisting of 5% by weight mixture of rare earth chlorides and 2% by weight of ammonium chloride for 2 treatments of 24 hours each. The aluminosilicate was then washed with water until the efiiuent contained no chloride ions, dried and treated with steam for 20 hours at 1125" F. at atmospheric pressure.

The catalytic evaluation of the resulting aluminosilicate for cracking gas oil at 900 F. is shown in the following table:

H wt. percent Ahoy-39.85 wt. percent, Si0244.9 wt. percent, Fe2Oa 0.35 wt. percent, TiO20.73 wt. percent, Ca0trace, Mg0 trace, Na2O0.12 wt'percent, K200.10 wt. percent.

44.51 wt. percent A1 03, 38.51 wt. percent SiO'2, 1.27 wt. percent F9203, 1.47 wt. percent T102, 0.08 wt. percent CAO, 0.12 wt. percent MgO, 0.08 wt. percent N n20.

A Advantage 10 RVP, vol. percent +4.2 Excess C s, vol. percent 5.0 C +gasoline, vol. percent +4.0 Total C s, vol. percent -4.8 Dry gas, wt. percent --0.5 Coke, wt. percent +0.3

EXAMPLE 24 Bentonite', an aluminosilicate, which had been caustic treated, was treated with an aqueous solution consisting of 5% by weight mixture of rare earth chloride and 2% by weight of ammonium chloride. The treated aluminosilicate was then washed with water until there was no chloride ions in the efliuent, dried and then treated with steam for 24 hours at 1200 F. at a pressure of 15 p.s.i.g. The resulting aluminosilicate contained 0.2% by weight sodium and possessed excellent catalytic properties.

What is claimed is:

1. A crystalline aluminosilicate characterized by:

(l) possessing rigid three dimensional networks of $0.; and A10 tetrahedra in which the tetrahedra are cross-linked by the sharing of oxygen atoms such that the ratio of total aluminum and silicon atoms to oxygen atoms is 1:2; and

(2) containing from 0.8 to 1.0 equivalent, per gram atom of aluminum, of ions of positive valence selected from the group consisting of hydrogen ions and ammonium ions, and calcium cations wherein the cations of calcium comprise between 40 and of the total equivalents of positive ions; and

(3) containing less than about 0.25 equivalent of sodium per gram atom of aluminum.

References Cited UNITED STATES PATENTS 2,983,670 5/1961 Seubold 252455 2,763,623 9/1956 Haensel 252455 3,006,153 10/1961 Cook 252455 3,130,006 4/1964 Rabo et al. 252-455 3,140,249 7/1964 Plank et al. 252455 3,140,322 7/ 1964 Frilette et al 252455 3,140,253 7/ 1964 Plank et al 208- 1,840,450 1/1932 Jaeger et al. 252454 2,253,285 8/ 1941 Connally 252455 2,617,712 11/1952 Bond 23112 2,882,244 4/ 1959 Milton 252455 2,916,437 12/1959 Gilbert 252455 2,962,435 11/1960 Fleck et al. 252455 2,971,904 2/1961 Gladrow et a1 23-113 2,982,719 5/ 1961 Gilbert et al. 252455 2,750,329 6/1956 Barrett et al 252460 2,909,568 10/ 1959 Gleim 252472 3,013,988 12/1961 Bukata et al. 252455 EDWARD J. MEROS, Primary Examiner US. Cl. X.R. 252455 32 3 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent no. 3,5 7 Dated APRIL 28, 1970 Inventor) VINCENT J. FRILETTE and PAUL B. WEISZ It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3, line 64,"the" should be --and--. Column 6, line I g, "mentionel" should be --mentioned--. Column 13, line 3, 'aluminosilicates" should be --aluminosilicate--; Column 13, line 11, "soluction" should be --solution--. Column 1 line 53, "+2.7" should be --+8.7--. Column 15, line 35 "16.6'! should be --6l.6--.' Column 18, line 59, "900C. should be --900F. Column 18, line 68, "0 's" should be --C s--. Column 20, line 12, "chloride" should be --chlorides--.

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